Floor product



Nov. 10, 1942. E. VAN DER PYI. 2,301,721

FLOOR PRODUCT Filed Aug. l, 1939 [-75.3 F7114 F7G.5

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EDWARD VANDR FYl.

M" L M/ Summa? Patented Nov. 10, 19424 UNITED. .STATES PA'rl-:m` A0ppm.;A

y mfglwi i i Edward van der Pyl, Holden, Mass., signor to Norton Company, Worcester, Maas., a corporation of Massachusetts 4 Animationen@ 1, 19:9, serial No. 287,691

scams;

The inveuon'remes to non-sup door products, particularly for use on stairs.

One object of the invention is to provide a Another object of the invention is to provide a composition for a metal floor product producing a piece which is highly resistant to wearv and also suiiiciently ductile so that it will not fracture even under abusive conditions. Another cbject of the invention is to provide a pracproduct. Other objects will be in part obvious or in part pointed out hereinafter.

'I'he invention accordingly consists inthe features of construction, combinations of elements, arrangements of parts, and in the 'severalsteps and relation and order of each of said steps to one or more of the others thereof, all as will be illustratively described herein, and the scope of the application of which will be indicated in the following claims. 5

In the accompanying drawing illustrating se eral possible embodiments of the mechanical features of this invention:

Figure 1 is an end view of a stair nosing';

Figure 2 is an end view of a stair nosing with a non-abrasive backing;

Figure 3 is a perspective view of the stair nosing of Figure 1 Figures 4 and 5 are perspective views of iloor products in rectangular parallelopipedal shape, the product of Figure 4 being rectangular in cross section .andthe product of Figure 5 being square in cross section;

Figure 6 is a view partly in end elevation and partlyv in cross section, of a composite structure consisting of a sheet metal backing plate and rectangular abrasive members having integral backings of non-abrasive metal.

I provide a quantity of abrasive. While any suitable abrasive may be used, such as sand, flint, garnet, crushed glass, or the like, I prefer the electric furnace abrasives or emery. `Emery is a natural variety of alumina and 'is sufiiciently' hard to make a good practical floor product. Electric furnace silicon carbide can also be used, but the preferred abrasive is electric furnace fused alumina which is sufliciently hard and at the same time tougher and stronger than silicon carbide or any of the other abrasives mentioned.

I provide a quantity of metal bond in powdered form, the chief ingredient of which is preferably copper. My preferred bond formula is: copper 76% by weight, nickel 20% by weight, and tin l is not the final product. tical method for the manufacture of such a floor 25 and the tin makes it just a little harder.

4% by weight. I provide these as separate powders and mix them together.

I make a mixture of the abrasive and bond, 50% of each by volume. I then place this in a mold the shape of the floor product to be formed. The mixture of powders and abrasive is then pressed in the mold by means of a hydraulic press, thereby producing a solid integral body which can be readily handled. This, however, I place .the pressed product in a sintering lfurnace and heat to a temperature below` the melting point of copper. preferably of the order of 800 C. for 5 hours. This heating sinters` the mixture of copper,

l nickel and tin and produces a homogeneous integral article.

The amount of tin selected is below that at which the product would be brittle or friable.

The nickel adds toughness to the product. I

prefer the non-ferrous metals because of the possibility of rusting. For many practical considerations, copper is the preferred basic ingredient o'i' the bond. The copper all alone is not tough enough, wherefore the nickel was added. But so far as the method is concerned, I may use any other metal powders. Figures 1 and 3 illustrate a stair nosing 9 entirely formed of abrasive bonded with metal according' to the invention andvwhich may be 'secured in any suitable or known manner to the lfront part of stairway steps.

If desired, a composite article may be made in which the lower part is metal without any abrasive and the upper part is metal plus abrasive,

this being done simply by the manner'of filling the mold. In Figure 2, a stair nosing lll is illustrated consisting. of metal bonded abrasive Il integrally secured to a metal backing I2.

The product is useful as a nosing for stair treads, for example on stairways of ships where secured to a stair or oor, while Figure 5 illustrates a parallelopipedal metal bonded abrasive piece Il which can readily' be inserted in slots provided, as well known, in metal stairways for this purpose. An article made in accordance with the invention is extremely strong 'as well as durable and it is not at all brittle but will bend to a considerable extent. The :door product is also useful in any place where a metal oor is used, oil is bound to be present, and itis desired to reduce the danger of accidents to persons by slipping. For example, the floor product is uselful for the floors of gun turrets for l; attleships, in electric lighting plants, around turbines and furnaces, in machine shops, around automatic screw machines etc.

The method of manufacture'v permits wide variation in the proportions of ingredients without any. mechanical difficulties. the abrasive may be concentrated where desired, simply by selectively illing the mold. '-As the molding is carried on without the use of heat, the production can be at a high rate and a small amount of mold equipment will suce. The

larticles as removed from the mold can be readily handled so the furnace runs can be postponed until a great number of articles are ready for Furthermore,

terpreted. as illustrative and not in a Hunting sense.

I claim: Y l. A oor product consisting of abrasive grains bonded with a sintered metal bond formed from metal powder and consisting oi' copper approximately 76%, nickel approximately 20%, and tin approximately 4%, the abrasive sintering. Thereby the method is economical 1 and practical.

Further with regard to the proportionsv of i metals used,l somewhere just above 15% of tin" producesa brittle copper alloy and so far as certain features of the invention are concerned, I desire to avoid this. Therefore, tin is preferably less than 15%. 'I'he copper should predominate but in order that the bond shall be tough, the nickel should be present in a. substantial amount, say in greater amount than the tin.

One advantage of making the article in two sections, as shown in Fig. 6, one part I5 including abrasive and the other part I6 including no abrasive, is that the lower portion- I6 including no abrasive can readily be machined and can, for example, be drilled and tapped. For instance, thereby a large floor can be laid by'providing metal tiles I5, I6 according to the invention as herein described, providing a large sheet of steel I'Ilwith holes I8 through it, drilling and tapping holes in the non-abrasive portion I6 of the tiles, and thereby attaching them with screws '20 to the sheet metal. A similar procedure may be adopted with the nosing I0 of Figure 2. y

It Will thus be seen that there has been provided by this invention a method and an article in which the various objects hereinabove set grains being well distributed throughout the 'metal bond forming a homogeneous aggregate.

2. A iioor product consisting o'f abrasive grains bonded with a sintered copper-nickel-tin bond formed from-metal powder in which copper predominates, tin is be'low the quantity at which friableness is imparted, and nickel is present in a substantial amount.. i. e. in greater percentage than the tin, the abrasive grains being well distributed throughout the metal bond forming a homogeneous aggregate.

3.-A oor product having a top portion consisting of abrasive grains and a sintered bond formed from powdered metal consisting of copper, nickel, tin in which copper' predominates,

tin is below the quantity at which friabieness is imparted, and nickel is present in a. substantial amount, i. e. in greater percentage than the tin, and a bottom portion consisting-of a copper, nickel, tin alloy, these metals being present in substantially the same proportions as they are present in the said bond, the two portions being integrally united and the product being a unitary piece, the abrasive grains being well distributed throughout the metal bond forming a homogeneous aggregate. f

' EDWARD VAN 'nan PYL. 

